Method of making moldable members



R. J. FORD ETA!- METHOD OF MAKING MOLDABLE MEMBERS Original Filed Feb. 11, 1963 July 15, 1969 5 Sheets-Sheet 1 INVENTORS ROBERT J. FORD TADEUSZ TARCZYNSKI ATTORNEY July 15, 1969 R. J. FORD ET AL 3,455,757

METHOD OF MAKING MOLDABLE MEMBERS Original Filed Feb. 11, 1963 5 Sheets-Sheet 2 r mg, m l r2 I I I9 $8 INVENTORS ROBERT J. FORD TADEUSZ TARCZYNSKI ATTORNEY July 15, 1969 FORD ET AL 3,455,757 I METHOD OF MAKING MOLDABLE MEMBERS Original Filed Feb. 11, 1963 5 eets-Sheet 5 HI]HIHHUHHIIHUHHb INVENTORS ROBERT J. FORD TADEUSZ TARCZYNSKI AT ORNEY July 15, 1969 J FORD ET AL METHOD OF MAKING MOLDABLE MEMBERS Original Filed Feb. 11, 1963 5 Sheets-Sheet 4 INVENTORS ROBERT J. FORD TADEUSZ TARCZYNSKI ATTORNEY July 15, 1969 R, FORD ET AL METHOD OF MAKING MOLDABLE MEMBERS Original Filed Feb. 11, 1963 5 Sheets-Sheet 6 R I Q9 0 W N T R Now E RU O T v 00 w, A NFR Q l A J.T

E RT United States Patent 3,455,757 METHOD OF MAKING MOLDABLE MEM BERS Robert J. Ford, Folsom, and Tadensz Tarczynskl, Upper Darby, Pa., assignors to The Boeing Company, Seattle, Wash., a corporation of Delaware Original application Feb. 11, 1963, Ser. No. 257,546, now Patent No. 3,237,697, dated Mar. 1, 1966. Divided and this application Oct. 21, 1965, Ser. No. 513,885

Int. Cl. B29c 17/04; B3211 17/04 U.S. Cl. 156214 8 Claims ABSTRACT OF THE DISCLOSURE A method of making moldable members such as airfoil structures for rotary wing aircraft. Plies of plastic reinforced materials are utilized for forming portions of an airfoil structure, especially the spar assembly and skin portions. The plastic reinforced materials are essentially composed of a moldable epoxy laminate reinforced with continuous filaments such as glass, which filaments extend either in biased or unidirectional relation to the filaments of adjacent plies. In one embodiment, an airfoil is formed in an operation utilizing the plastic reinforced materials and, in another embodiment, a spar assembly for an airfoil is attached to a connecting member in a similar operation.

This application is a divisional application of our US. patent application, Ser. No. 257,546, filed Feb. 11, 1963, now U.S. Patent No. 3,237,697 granted Mar 1, 1966.

This invention relates to a method of manufacture and, more particularly, to the manufacture and construction of lightweight rotor blades for rotary wing aircraft in which moldable reinforced materials are utilized in a unique manner to lend the necessary directional strength characteristics to the blade.

The general advancement of rotary wing technology has resulted in increased requirements for the rotor blades employed on rotary wing aircraft. It has been a need in the art of rotary blades to develop rotor blades, which are economical to manufacture, non-corrosive, and characterized by improved fatigue properties. Additionally, rotor blades have been desired, which have the characteristic of being lighter in weight per unit area of lift surface while having the required stiffness and strength. Accordingly, the advance of the technology of plastics has given impetus to development of a plastic rotor blade, which is characterized by the above enumerated advantages. This invention relates to such a rotor blade.

In accordance with preferred practice of the present invention, it has been found that the art of plastic rotor blade manufacture can be vastly improved by selective orientation of plies of moldable laminated materials reinforced with unidirectionally aligned filaments such as glass, yarn, or metal. This is in contradistinction to the use of fabric or woven materials as reinforcements. That is, the fill (threads perpendicular to the primary strength filaments) of the fabric or woven reinforcements offers some support but little strength to the reinforcement, and actually represents wasted and unnecessary weight. Also, when incorporated in moldable materials utilized in the manufacture of the rotor blades, the fill tends to cause a notch elfect, which is not encountered with unidirectional filaments. Accordingly, the term plastic reinforced materials as used herein has particular relation to plastic or resinous materials incorporating unidirectionally aligned, non-woven filaments.

In this connection, various commercially available materials such as plastic or resinous sheet materials reinforced With linearly aligned glass or cord filaments may 3,455,757 Patented July 15, 1969 be employed in accordance with the present invention. One suitable material for this purpose is a reinforced plastic, Type 1002, manufactured and sold by Minnesota Mining and Manufacturing Co. under the trademark Scotchply. Although the properties and characteristics of this material are described in more detail in Bulletin No. 2A, dated Dec. 1, 1957, published by Minnesota Mining and Manufacturing Co., it is essentially a moldable epoxy laminate reinforced with continuous, non-woven glass filaments. This material is available either in single plies with the filaments runinng unidirectionally, or in multiple plies with the filaments arranged in biased relation. Each ply is about 0.010 inch thick. Under heat and pressure the material becomes thermoplastic and the plies are highly susceptible to bonding together into unitary relation.

The present invention utilizes plies of plastic reinforced materials for forming portions of a rotary blade and, particularly, the spar assembly and the cover or skin thereof. The plies are laminated and bonded together to obtain plastic members with filaments running either in biased or unidirectional relation to the filaments of adjacent plies. Further, the plies of the blade skin are arranged in staggered relation throughout the length of the blade according to the desired strength, weight, and contour requirements for the blade. The plies also are combined with other lightweight elements in a unique manner to lend the desired directional strength characteristics to the blade at various points throughout and to form a resultant blade of unitary structure.

It is an object of this invention to provide for a process of manufacturing airfoil structures that is low cost, efficient, and requires a minimum number of steps; furthermore, the method of the invention utilizes the directional strength characteristics of reinforced plastic material to produce a lightweight airfoil structure having laminations of the plastic material selectively oriented and arranged to most effectively absorb stresses and loading therein.

It is another object of this invention to provide for a method of manuafcturing plastic rotor blades for rotary wing aircraft following a unique sequence of steps in which the elements thereof are united in a single forming tool having a variable contour and wherein the rotor blade, subsequent to formation, may be balanced to establish the desired center of gravity and weight distribution.

Other Objects of this invention will be readily perceived from the following description, drawings, and claims.

This invention relates to a method of forming a structure of airfoil contour in which a leading edge assembly is placed within a mold cavity defining the exterior contour of the structure. The method further includes the steps of forming a skin section by placing plies of moldable reinforced material Within the mold cavity to provide a leading end behind the leading edge assembly and trailing ends extending along opposite walls of the mold cavity, and bonding the skin section and the leading edge assembly together. Additionally, a spar assembly is positioned in the mold and against the leading end of the skin section. Further, the method includes the steps of filling substantially the remainder of the space within the skin section and the spar assembly 'with lightweight material and bonding the skin section, the leading edge assembly, the spar assembly, and the lightweight material to form a structure having an airfoil contour conforming to that of the mold cavity.

This invention further relates to a method of forming a spar assembly for a blade structure of airfoil contour having a connecting member at one end thereof. The method comprises the steps of pre-forming a spar support portion of elongated cylindrical configuration and is connected relation to the connecting member, and placing ice plies r reinforced plastic material in surrounding relation to the spar support member with the reinforcement of at least a portion of the plies extending unidirectionally, and substantially parallel to the longitudinal axis of the spar support member and the blade structure. These steps are followed by the step of molding the spar support member and the plies into unitary relation.

The attached drawings illustrate a preferred embodiment of the invention, in which:

FIGURE 1 is a plan view of the present invention in the form of a rotor blade for rotary wing aircraft;

FIGURE 2 is a sectional view taken on line 2--2 of FIGURE 1;

FIGURE 3 is a sectional view taken on line 33 of FIGURE 1;

FIGURE 4 is a view partly in section taken on line 44 of FIGURE 1;

FIGURE 5 is a sectional view taken on line 55 of FIGURE 1;

FIGURE 6 is a sectional view taken on line 6-6 of FIGURE 1;

FIGURE 7 is a sectional view taken on line 77 of FIGURE 1;

FIGURE 8 is a longitudinal sectional view of the root end socket taken on line 88 of FIGURE 1;

FIGURE 9 is a schematic view of plies of plastic material in biased relation;

FIGURE 10 is a schematic sectional view taken on line 10-10 of FIGURE 9;

FIGURE 11 is a schematic view of plies of plastic material in unidirectionally aligned relation;

FIGURE 12 is a schematic sectional view taken on line 1212 of FIGURE 11;

FIGURE 13 is an enlarged, fragmentary view illustrating the staggered relation between plies of material forming the outer skin of the rotor blade in accordance with the present invention;

FIGURE 14 is an enlarged, fragmentary view of a preferred form of core section employed in accordance with the present invention;

FIGURE 15 is an enlarged, fragmentary view, partially in section, of the outboard end of the blade portion and the tip end assembly;

FIGURE 16 is an end view representing the relative disposition between parts in the formation of the leading edge section assembly according to the method of the present invention;

FIGURE 17 is an end view illustrating the relative disposition between parts in the formation of the outer skin layer according to the method of the present invention;

FIGURE 18 is an end view illustrating the relative disposition between parts in a mold for forming the spar assembly; and

FIGURE 19 is an end view representing the relative disposition and arrangement between parts in the final molding stage according to the method of the present invention.

Referring to the drawings and particularly FIGURE 1, there is shown an airfoil structure, which broadly comprises a blade portion 10 of airfoil contour and a root end portion 12. As seen in FIGURES 1 and 4 to 7, the blade portion 10 includes a leading edge assembly 14, a main supporting element in the form of a spar assembly 16 and blade skin or cover layer 15.

The spar assembly 16 is enclosed by the skin 15 and secured at its inboard end to a root end socket 17, and a lightweight filler element or core 18 is enclosed within the skin 15 and the spar assembly 16. The trailing edges of the skin 15 are bonded to a trailing edge wedge 19 to captivate the core 18. The core 18 and the trailing edge wedge 19 traverse substantially the entire length of the blade portion 10 and terminate at a root rib 20 and a tip end assembly 21 at the inboard end and the outboard end, respectively. Additionally, a clamp 22 is employed on the root end 12 of the blade structure for providing structural support and connection means for a d mp o s o Preferably, the leading edge assembly 14 is positioned exteriorly of the skin layer 15 and traverses the entire leading edge of the blade portion 10. Accordingly, the leading edge assembly 14 provides a rugged exterior portion resistant to the detrimental effects of the environment encountered during use. Essentially, the leading edge assembly 14 comprises an abrasion strip 30 of, for example, stainless steel and a rounded nose portion 24, which defines the contour of the leading edge of the blade.

The nose portion 24 is formed of a rugged plastic material and has a longitudinal bore 25, which extends therethrough for receiving a tapered, removable balance rod of weight 13. The abrasion strip 30 is applied over the rounded nose 24 for providing an outer protective surface and has trailing edges 32, which terminate in overlapping relation with the leading end of the skin 15.

A bearing block 26 is positioned at the inboard end of the nose portion 24, and a stop member 27 (see FIGURE 15) is positioned at the outboard end thereof. The bearing block 26 and the stop member 27 fixedly hold the balance rod 13 within the bore 25 of the nose portion 24. That is, an end nut 29 (see FIGURE 1) is threaded to an inboard portion of the balance rod 13 that extends through a bore in the bearing block 26, which has the same configuration as the nose portion 24. However, the bearing block 26 is formed of a stronger material than the nose portion 24 in order to withstand centrifugal forces from the balance rod 13 during rotor blade use. Accordingly, the stop member 27 coacts with the bearing block 26 to counteract the centrifugal forces on the balance rod 13.

The leading edge assembly 14 includes a mass balance Weight 35, which is permanently secured to the nose portion 24 by means of a plastic filler 36. The weight 35 tapers as it extends inboard from the outboard end of the blade, and it traverses the greater length of the blade to approximate the necessary balance of the blade. Of course, since the filler 36 need not withstand torsional stresses it is formed from plastic plies having unidirectionally aligned filaments.

It should be understood that the balance rod 13 is preferably tapered or formed as desired to achieve the necessary blade balance and inserted into the bore 25 after the blade is formed. Additionally, the balance rod is tapped at its outboard end to facilitate removal thereof.

The covering for the blade portion defined by the skin 15 is composed of a plurality of plies of a plastic or resinous material reinforced with linearly aligned filaments. In the skin layer 15, the plies, such as plies 15' and 15" of FIGURE 9, are preferably arranged with the filaments of adjacent plies extending in biased relation to one another. For the purpose of illustration and as shown sche matically in FIGURE 9, the bias angle may be on the order of degrees between the reinforcing elements of each adjacent ply. Accordingly, the reinforcing filaments extend at an angle on the order of 45 degrees with respect to the leading and trailing edges of the blade when laid longitudinally thereof. It should be understood that each ply contains a plurality of filaments such as filaments 95, as seen in FIGURE 10. Each filament of a ply extends linearly and unidirectionally with respect to each other filament of its ply. Accordingly, since the plies of the skin layer 15 are laid in biased relationship, the filaments 95 of a first ply, such as 15', extend in biased relationship with respect to the filaments of adjacent plies, such as ply 15", when bonded together. Further, it should be understood that the plies, such as plies 15' and 15", are laid and bonded so as to approximate the contour desired.

Additionally, as best seen in FIGURE 13, the plies of the skin layer or skin 15 are laid in staggered, length-wise relation along the length of the blade portion to achieve the desired blade weight and torsional stiffness, as well as the desired contour of the blade portion 10. In crosssection, as shown in FIGURES 4 to 7, the skin 15 comprises a leading edge portion 38 abutting against the lead-. g g a se bly 14 and enclo ed within the ab as on strip 30 along with rearwardly extending surfaces 39, which terminate in rearwardly convergent trailing end surfaces 40.

The spar assembly 16 traverses the entire length of the rotor blade and is defined by a plurality of plies 42 and 44 (see FIGURES 2, 3, and 8). Additionally, the plies 44 are composed of plastic reinforced material and the reinforcements thereof extend the entire length of the blade structure from the root end socket 17 to the outer tip end assembly 21.

As may be clearly seen by reference to FIGURE 8, the root end socket 17 has an hour-glass shaped portion upon which the plies 42 and 44 are laid in surrounding relation so as to form a generally hour-glass shaped section. Thereafter, the plies 42 and 44 continue outwardly in the form of a closed circular cross-section (see FIG- URE 2) and then in the form of a D-spar cross-section (see FIGURES 3 and 4). However, as noted from FIG- URES 5 to 7, the plies 44 undergo a transition from the D-spar to a C-spar configuration. The spar gradually decreases in thickness so as to taper outwardly from the inboard end to the tip end of the blade.

Since the spar is the main load-carrying element of the blade, each of the plies 44 thereof is preferably reinforced with longitudinally extending, linearly aligned filaments in closely spaced relation so as to effectively absorb centrifugal forces imparted to the blade during use. That is, in the spar portion comprised of the plies 44, plies such as plies 44' and 44" are preferably arranged with the filaments of adjacent plies extending unidirectionally with respect to each other.

For the purpose of illustration and, as shown schematically in FIGURE 11, spar plies, such as plies 44' and 44", are laid in unidirectional relation and each contains a plurality of filaments such as filaments 48 (see FIG- URE 12). The filaments in each ply are linear and unidirectional. Accordingly, the filaments of a ply, such as ply 44, are in unidirectional relation to the filaments of an adjacent ply, such as the ply 44". Further, it should be understood that the plies 44' and 44" are laid and bonded so as to approximate the contour desired.

As illustrated in FIGURES 2, 3, and 8, an inner core mandrel or support member 45 is positioned within the root end socket '17 in order to locate the layup of the plies 42 and 44 at the outboard end of the blade socket 17. As shown in FIGURES l to 5, the support member 45 extends a limited distance through the blade portion and terminates in an outer end portion 46. Preferably, the inner core support member 45 is composed of a lightweight moldable material such as polyurethane foam, which may be effectively formed in place within the root end socket 17 (see FIGURE 8).

Additionally, the support member or core mandrel 45 incorporates a kick rib element 47 therein (see FIGURE 4) to cooperate with the spar plies 42 and 44 in absorbing kick loads imposed on the blade. The kick rib 47 is preferably formed of plies of reinforced plastic material laid in biased relation similar to the skin (see FIG- URES 9 and 10) and positioned in the support 45 in transverse relation to the major longitudinal axis of the blade portion 10 (see FIGURE 4). It should be understood that the kick forces are a result of centrifugal forces. Since the reinforcing filaments of the spar are not formed in a straight line when the spar is bonded but conform to the desired contour (see FIGURES 2 to 4), centrifugal forces thereon tend to urge the filaments to straighten into a straight line. Accordingly, these kick forces tend to compress the spar.

The plies 42 are interpositioned between the spar plies 44 and internal blade structure such as the root end socket 17 and the support member 45. However, the plies 42 only extend from the blade socket 17 to the end 46 of the support member 45. The plastic material composed of the plies 42 has, for its main purpose, the absorption of torsional loads imparted by the blade to the root end socket 17, and each of the plies isreinforced with unidirectional filaments. The filaments of adjacent plies are arranged in biased relation similar to the skin '15 (see FIGURES 9 and 10) so as to most effectively withstand the torsional loads applied thereto.

As may be seen by reference to FIGURE 8, a circular, rubber-like grommet 50 is interpositioned between the outer end of the blade socket 17 and the bias-laid plies 42. The main purpose of the grommet 50 is to insure that the forces arriving from the plastic blade by way of the plies 42 are distributed into a greater portion of the root end socket 17 rather than merely into the outboard end thereof. Of course, the grommet 50 may also be formed of other materials, which have a low modulus of elasticity such as plastic or resinous materials reinforced with unidirectional filaments aligned in the direction of grommet periphery.

As may be understood by reference to FIGURE 5, a plastic filler 52 extends from the inboard end of the blade portion 10 to the end 46 of the support 45 and between opposite skin portions 39. Accordingly, the filler 52 lends added strength to the spar along the inboard end of the blade portion as it opens to a C-spar as well as lending added rigidity and vertical strength to the blade between the upper and lower skin layers 39. In this general relation, it may be noted by reference to the spar crosssection in FIGURES 2 to 7, that the spar assembly affords the desired strength, weight, and stiffness for the blade throughout its length by selective orientation of the plies 42, and 44, and the filler 52 so as to most effectively withstand various stresses and loading imposed on the blade. Additionally, it should be understood that the plies 42, the filler 52, the spar plies 44, and the plies of the skin 15 are bonded together into unitary relation.

It should be understood that the term spar assembly, as employed herein, refers to one or more of the following: the spar support member 45, the kick rib 47, and the plies 42 and 44, and the filler 52. Additionally, it should be understood that the term adjacent, as utilized in the description of the relative positions of plies of plastic material, should not be limited to the juxtaposed ply. That is, while it is preferable to position plies of the skin 15 at a bias with respect to juxtaposed plies, the arrangement of the plies may be varied as desired. Accordingly, for example, a first preselected number of plies, which are laid in juxtaposed relationship, may employ reinforceable filaments that extend unidirectionally with respect to each other, and a second preselected number of plies adjacent to the first preselected number may employ reinforcing filaments, which are unidirectional with respect to each other but laid on a bias with respect to the filaments of the adjacent first preselected number of p res.

The remainder of the blade portion 10 is preferably filled with the cellular core 18, which is placed within the spar and the skin 15. At the inboard end of the blade portion 10, the core or core setcion 18 is positioned directly between the filler 52 and the trailing edge wedge 19 as shown in FIGURE 5. Outboard of the end 46 of the support member 45, the core or core section 18 is positioned within the skin 15 and the plies 44, which comprise the spar (see FIGURES 6 and 7).

As shown in FIGURES 1 and 14, the core section 18 preferably is comprised of a series of spaced honeycomb panels 56 being interconnected by transverse ribs 57 bonded to the ends of the panels 56. The panels 56 are defined by a series of interconnected vertically extending cells 58, and each of the ribs 57 is defined by a series of horizontally extending cells 59, which extend perpendicularly to the cells 58 of the panels 56. The cells 59 are bonded to plates 53 and 54, forming sandwich panels, which are bonded to the panels 56; however, the ribs 57 may comprise a single sheet of material if desired. It should be understood that the panels 56 may decrease in width as the honeycomb extends outboard 7 from the inboard end thereof to provide added strength as the skin 15 and spar 16 taper.

The core 18 is captivated within the spar and the skin 15 of the blade by the trailing edge wedge 19, which is bonded between the trailing ends 40 of the skin layer 15. Of course, since the trailing edge Wedge 19 need not absorb torsional stresses, it also is preferably formed of a plurality of plies of plastic material, which are reinforced by a plurality of unidirectionally extending filaments in a manner similar to the plies 44 (see FIGURES 11 and 12).

As clearly illustrated in FIGURE 1, the root rib 20 is positioned at the inboard end of the blade portion (see FIGURE 4) to close the inboard end of the blade; the tip end assembly 21 includes a transversely disposed tip rib 60 so similar to the root rib 20 to close the tip end of the blade portion. Additionally, the tip rib 60 supports the tip end assembly 21 in connected relation to the blade. Both the root rib 20 and the tip rib 60 are preferably formed of a plastic material reinforced with unidirectional filaments arranged in biased relation so as to lend some additional support and transverse rigidity to the blade in a manner similar to the skin (see FIG- URES 9 and 10).

The tip end assembly 21 mounted on the tip rib 60 includes tracking weights 62 and 63 attached to the tip rib 60 by means of brackets 64 and studs 65. Additionally, the stop member 27 also is fixedly secured to the tip rib 60 along the leading edge of the tip end assembly 21 to secure the outboard end of the balance rod 13 by means of a plurality of fasteners 66. Protection of the outermost end of the tip end assembly 21 and the outboard end of the blade portion 10 is achieved by means of a skin or cover 68, which also is constructed of plastic material reinforced with filaments laid on a bias. The tip cover 68 is attached to the blade by a plurality of fasteners such as screws, which are inserted through apertures 70 to engage the studs 65 and by a screw 70, which secures the trailing edge portion of the cover 68.

As seen in FIGURE 1, a clamp 22 is secured over the root end of the spar assembly and over the hour-glass portion of the root end socket 17 in order to insure a strong structural support thereof. The clamp 22 includes a plurality of attachments such as cars 75 for receiving fastening means. The cars 75' and 75" are also adapted to serve as a means for attachment to a damper arm (not shown). If a connection to a damper arm is not necessary, it is apparent that other suitable means may be substituted for the clamp 22. That is, for example, filament wound reinforced plastic preferably wound on a bias could be suitably employed to achieve the desired hoop stress andsupport in hour-glass area.

In forming the rotor blade structure, the root end portion 12 and the blade portion 10 are preferably formed and bonded into unitary relation within a single mold. Reference may be made to a copending application of Robert J. Ford and George H. Guckes entitled Molding Apparatus, Ser. No. 257,647 filed Feb. 11, 1963, now U.S. Patent No. 3,171,163 granted Mar. 2, 1965, and assigned to the assignee hereof, for a more detailed description of a mold and forming mandrels used in conjunction therewith which are adapted for use in the formation and construction of the plastic rotor blade. Accordingly, FIGURES 12 to 15 illustrate only so much of the mold and forming mandrels as are necessary for an understanding of the method carried out in constructing a rotor blade.

In the initial stage, the parts comprising the leading edge assembly, except for the removable balance rod 13, are bonded together in a mold 80 as represented in FIG- URE 16. Prior to assembly in the mold 80, the parts are chemically cleaned, and an adhesive, such as an epoxy resin, that is compatible with the leading edge elements is applied thereto. Then, in succession, the abrasion strip 30, the nose portion 24, the plastic filler 36, and

the mass balance weight 35 are symmetrically located along the bottom or leading end surface of the mold cavity and against a mold liner 82.

A forming mandrel 83 is then clamped within the mold to apply a downward uniform pressure against the leading edge assembly. Sufiicient bonding pressure is applied to the mandrel 83 to insure a good bond as the mold is heated to an elevated temperature. For put poses of example, the bonding pressure may be about 30 to 40 pounds per square inch and the temperature approximately 330 F. After bonding, the leading edge assembly 14 is cleaned and prepared for the second step in which the skin ,15 is formed and bonded to the leading edge assembly 14.

The outer skin layer 15 is formed by positioning plies of the plastic reinforced material symmetrically within the mold and with the reinforcing filaments arranged in biased relation to one another (see FIGURES 9 and 10). That is, rather than laying the plastic so that the filaments of adjacent plies are unidirectional to one another, the filaments or strands in the plies extend at a preselected angle on the order of 90 degrees with respect to the filaments of the adjacent plies. In this manner, the high strength characteristics of the material are not wasted in directional regions of low stress as would be the case in using fabric or woven reinforcing materials. Additionally, as best seen from FIGURE 13, the plies are staggered along the length of the blade so that the skin thickness tapers outwardly from the inboard end to the tip end and is regulated to afford the desired stiffness and weight to the skin 15 and the blade portion 10.

In assembled relation within the mold 80, the plies of the skin 15 are located symmetrically about the center line of the mold with the leading end surface 38 abutting against the leading edge assembly 14. The sides 39 and the trailing ends 40 of the skin 15 extend upwarly along opposite sides of the mold cavity and the liner 82 so that the skin 15 is cured into the rotor blade configuration.

In the molding operation of the skin 15, a forming mandrel having a pressure bag 85 and stringer 86 therein are positioned within the plies of the skin 15 and clamped to the upper or trailing end of the mold, which is par.- tially closed. Again, the molding is carried out under the application of heat and pressure. Additionally, steam pressure or other suitable pressure medium is applied Within the pressure bag at a pressure, for example, of 30 pounds per square inch at approximately 330 F. Accordingly, the plastic skin 15 is forced outwardly against the contour of the mold. Thus, the skin 15 assumes the desired shape, and the leading end portions 38 thereof are bonded to the leading edge assembly 14. However, it should be understood that the trailing ends 40 of the skin 15 are not bonded together and, accordingly, provide an entrance for subsequent insertion of the spar assembly, the core 18, the root and tip ribs 20 and 60, and the trailing edge wedge 19.

The spar assembly is desirably formed by first molding the inner support member .45 into connected relation with the root end socket 17 and has the kick rib or spar rib 47 incorporated therein. As previously described, the support 45 primarily serves as a former for the purpose of locating and positioning the plies 42 and 44 in desired relation and extends from the root end of the spar to the outboard end 46 of the support 45 (see FIGURE 1). The support member 45 is preferably formed of a foam or other cellular material having suflicient density and strength to sustain the spar plies 42 and 44 during molding and the abiilty to withstand bonding temperatures. During the step of curing the spar, a separate forming mandrel 88 is used in cooperation with and outboard of the support 45 for locating and positioning the outboard plies 44 in desired relation. After the plies 42 are laid upon the root end socket 17 and the support member 45, the plies 44 are applied and located over the root end socket 17, the Support member 45, and the outboard mandrel 88. Of course, the plies 44 outboard of the support 45 are staggered lengthwise along the mandrel 88 in much the same manner as the skin so as to be of outwardly tapering thickness. However, in laying the plies 44 along the core support 45 and the mandrel 88, the reinforcing filaments of adjacent plies are oriented in unidirectional, longitudinally extending relation (see FIG- URES 11 and 12).

The entire assembly is then inserted into the mold with the outer, leading edge of the assembly abutting against the inner surface of the skin 15 (see FIGURE 18). Again, the upper end of the forming mandrel 88 is clamped to the upper or tailing end of the mold 80. Thereafter, the mold 80 is heated to an elevated temperature of about 330 F., and pressure of, for example, 30 to 40 pounds per square inch is applied through the forming mandrel 88 in cooperation with the mold 80. Following completion of the cure, the assembled spar skin, and leading edge sections are allowed to cool before removal from the mold 80 for cleaning and preparation for the final molding step.

In the final stage, the assembled and molded sections of the blade are removed from the mold and are positioned in a separate support stand (not shown) in a manner to hold the trailing ends 40 of the skin 15 open to a suflicient extent to permit insertion of the core 18. Prior to insertion, the core 18 is treated with an adhesive such as epoxy resin for subsequent bonding within the skin 15. Thereafter, the root rib 20 and the tip rib 60 are secured to the inboard and outboard ends, respectively, of the assembled blade portion 10, and the trailing edge wedge 19 is positioned between the trailing portions 40 of the skin 15. It should be understood that the root rib 20, the tip rib 60, and the trailing edge wedge 19 are preferably pre-formed and then bonded together in the final stage of the molding operation.

Upon assembly of the parts, the blade structure is inserted into the mold to assume the relationship as shown in FIGURE 19, and sufficient heat and pressure are applied to insure complete bonding, especially between the skin 15, the core 18, the root rib 20, the tip rib 60, and the trailing edge wedge 19. To insure proper bonding of the honeycomb core 18 to the interior surfaces of the spar and the skin 15, a vacuum pressure bag may be wrapped about the spar and skin assembly to evacuate the cells of the honeycomb core 18.

Since the vacuum pressure will exert forces perpendicular to the surfaces of the blade, such pressure will have both parallel and perpendicular components of force with respect to the longitudinal axes of the honeycomb cells 58. However, a small area extending spanwise of the blade and in a substantially central region of the blade chord, where the skin 15 extends perpendicular to the longitudinal axes of the honeycomb cells 58, is free of such a perpendicular component. While, the honeycomb cells 58 are capable of withstanding the component of force, which is parallel to the longitudinal axes thereof, the perpendicular component has a tendency to cause the honeycomb core 18 to collapse towards the above mentioned central region of the blade chord. However, the ribs 57, which are bonded between the core panels 56, add strength in the direction of the component perpendicular to the axes of the honeycomb cells and overcome the tendency of the core 18 to collapse.

Following the final stage operation, the blade is permitted to cool and then removed from the mold and trimmed. Thereafter, the balance rod 13, the tracking weights 62 and 63, the tip cover 68, a trim tab 72, and the clamp 22 are installed.

It should be understood that, depending upon the composition of the various sections, a number of steps may be combined or altered. That is, the steps (A) bonding the leading edge assembly, (B) forming the skin section, (C) forming the spar assembly, and (D) bonding the core, root and tip ribs, and trailing edge wedge may be combined in a single step. Additionally, steps (A), (B), and (C) may be combined or steps (A) and (B) may be combined while steps (C) and (D) are or are not combined as desired. In this manner, several or all of the mandrels may not be employed. However, great care is necessary to insure that the components of the blade are assembled into proper relative position prior to binding.

It is generally preferred to pre-form the spar assembly and to mold it seperately to the assembled leading edge assembly 14 and skin 15. Additionally, it is desirable to avoid the combination of steps (B) and (C) to insure that suflicient pressure is applied against the internal surface of the skin for forming into its desired contour. Furthermore, it is preferable to conduct step (D) separately since the more interior filaments of the plastic reinforced material of the skin 15 may have the tendency to take on the external configuration of the honeycomb core and some of the filaments may be forced into the honeycomb core cell cavities. However, as this invention contemplates, if step (D) is combined with other steps, the core 18, which may for example be polyurethane foam or other cellular material, requires suflicient stifiness to support the skin 15 and other blade components during bonding and to maintain proper pressure on the skin during bonding without damaging the filaments thereof. However, it should be understood that core material having a higher density with respect to honeycomb may cause undesirable blade balancing problems.

From the foregoing, it can be clearly understood that the rotary blade and the method therefor encompass numerous advantages hitherto unavailable. That is, the plastic blade is low in cost, non-corrosive, and has improved fatigue properties since there is less vulnerability to the occurrence of notches therein. Additionally, the blade is light in weight, and aerodynamically smooth. Of course, the capability of blade balancing, subsequent to formation of the blade, is an advantage of high importance in the art of rotary blades. That is, it can readily be seen that the feature of a removable balance weight allows incremental forming of the weight along the length thereof for accurate blade balancing. This is particularly true of the use of a rod as the balance weight since it may be formed easily by turning. When a removable balance weight is not employed the blade balance must be calculated prior to forming, which, of course, is less accurate than balancing after blade formation.

For purposes of exemplification, a particular embodiment of the invention has been shown and described according to the present understanding thereof. However, it will be apparent that changes and modifications in the invention hereof may be resorted to without departing from the spirit and scope of the invention.

We claim:

1. The method of forming a structure of airfoil contour comprising the steps of placing a leading edge assembly within a mold cavity defining the exterior contour of structure, forming a skin section by placing plies of moldable reinforced material within the mold cavity to provide a leading end behind the leading edge assembly and trailing ends extending along opposite walls of the mold cavity, bonding the skin section and leading edge assembly together, molding a spar assembly in the mold and against the leading end of the skin section and filling substantially the remainder of the skin section and the spar assembly with lightweight material, and bonding the skin section, the leading edge assembly, and the spar assembly to the lightweight material to form a structure having an airfoil contour.

2. The method of forming a structure of airfoil contour comprising the steps of placing a leading edge assembly within an open mold cavity defining the exterior contour of the structure, forming a skin section by placing plies of moldable reinforced material within the mold cavity to provide a leading end behind the leading edge assembly and trailing ends extending along opposite walls of the mold cavity, bonding the skin section and the leading edge assembly together, molding a spare assembly in the mold and against the leading end of the skin section, filling substantially the remainder of the space Within the skin section and the spar assembly with a core, placing root and tip ribs between the longitudinal extremities of the skin section and a trailing edge wedge at the trailing ends of the skin section, and bonding the spar assembly and the skin section to the core, the ribs, and the trailing edge wedge to form a structure having an airfoil contour conforming to that of the mold cavity.

3. The method of forming a structure of airfoil contour comprising the steps of placing a leading edge assembly within a mold cavity defining the exterior contour of the structure, forming a skin layer by placing plies of moldable material within the mold cavity to provide a leading end behind the leading edge assembly and trailing ends extending along opposite walls of the mold cavity, bonding the leading edge assembly and the skin layer together Within the mold, inserting a spar between the trailing ends of the skin layer and against the leading end thereof and bonding the spar and the skin layer together, filling substantially the remainder of the space within the skin layer with a core material, closing the mold cavity and bonding the trailing ends of the skin layer and the spar to the core material to form a structure having an airfoil contour conforming to that of the mold cavity.

4. The method of forming a structure of airfoil contour comprising the steps of forming a skin section by placing plies of plastic reinforced material within an open mold cavity defining the exterior contour of the blade to provide a closed leading end and trailing ends extending along opposite Walls of the mold cavity, partially closing the mold cavity, curing the skin section to conform to the mold cavity, preforming a spar assembly to conform to the contour of the leading end of the skin section, inserting the spar assembly between the trailing ends of the skin section and against the leading end thereof and molding the spar assembly and the skin section together, filling substantially the remainder of the space within the skin section with a lightweight material, closing the mold cavity, and molding the trailing ends and the lightweight material together to form a structure having an airfoil contour conforming to that of the mold cavity.

5. The method of forming a spar assembly for a blade structure of airfoil contour having a connecting member at one end thereof comprising the steps of pre-forming a spar support portion of elongated cylindrical configuration and in connected relation to the connecting member, placing plies of reinforced plastic material in surrounding relation to the spar support member with the reinforcement of at least a portion of the plies extending unidirectionally and substantially parallel to the longitudinal axis of the spar support member and the blade structure, and followed by molding the spar support member and the plies into unitary relation.

6. The method of forming a structure of airfoil contour comprising the steps of forming a skin section by placing plies of reinforced plastic material Within an open mold cavity defining the exterior contour of the structure to provide a closed leading end and trailing ends extending along opposite walls of the mold cavity with layers of reinforcements placed in biased relation with respect to adjacent layers thereof, molding the plastic material of the skin section into a unitary member, pre-forming a spar support portion of elongated configuration and in connected relationto a connecting member, placing plies of reinforced plastic material in surrounding relation to the spar support member and extending the length of the skin section with the reinforcement of the plies extending unidirectionally parallel to the longitudinal axis of the spar support member, and molding the spar support member, the plies thereof, and the plies of the skin section into a unitary member.

7. The method of forming a spar assembly for an aircraft rotor blade structure having a root end connection socket comprising the steps of pro-forming a spar support member of elongated cylindrical shape with one end thereof in connected relation to the root end connection socket, positioning first plies of reinforced moldable material in surrounding relation to the root end connection socket and to the spar support member and arranging the plies with the reinforcement extending in biased relation to the reinforcement of adjacent plies, placing second plies of reinforced moldable material in surrounding relation to the first plies and extending the second plies outwardly beyond the first plies in lengthwise staggered relation, aligning the second plies with the reinforcement thereof extending substantially unidirectionally along the longitudinal axis of the rotor blade structure, and followed by molding the spar assembly together into unitary relation.

8. The method of forming a composite aircraft blade structure comprising the steps of placing plies of curable plastic reinforced material within an open mold cavity in which the walls of the mold cavity define the exterior contour of the blade structure, locating the plies along the walls of the mold cavity to form a closed leading end and spaced trailing ends, partially closing the mold cavity and molding the plies to form the cover of the blade, inserting a spar assembly formed of reinforced plastic material within the cover against the leading end thereof and molding the spar assembly into unitary relation against the leading end of the cover while maintaining the trailing ends in spaced apart relation, inserting core material and a trailing edge between the trailing ends, closing the mold to unite the trailing ends of the cover and the trailing edge, and molding the cover to the core and the trailing edge to form a unitary blade structure.

References Cited UNITED STATES PATENTS 2,588,570 3/1952 Pitcairn 156-2l4 XR 2,609,883 9/1952 Daland 1562l4 XR 2,630,868 3/1953 Ellenberger 156-245 XR 3,000,446 9/ 1961 Warnken ll59 3,028,292 4/1962 Hinds 156214 3,097,982 7/1963 Stoner 156-292 XR FOREIGN PATENTS 871,625 6/ 1961 Great Britain.

EARL M. BERGERT, Primary Examiner G. W. MOXON H, Assistant Examiner 

